Motorized positioning apparatus for a seating unit

ABSTRACT

A motorized positioning apparatus for a seating unit includes a motor assembly that is configured to move a linkage assembly though a series of positions that arrange the seating unit in a closed position, open position, or extended position. The motor assembly attaches directly to a footrest drive link by way of a mounting tube. In addition, the motor assembly may attach either to a base rail of the seating unit or to a rear pivot link by way of a rear mounting tube.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/136,413, which was filed on Mar. 20, 2015.

BACKGROUND

Furniture conventionally known as “zerowall” furniture are thosearticles of furniture, such as, for example, recliner chairs, whereinthe rear portion of the chair can be disposed close to a wall of a roomsuch that when the chair is to be moved from its original or normalclosed or upright position, to its fully open reclined position, theentire body of the chair is moved forwardly so as to permit the seatback and the headrest portion of the chair to be inclined withoutnecessarily coming into contact with, and thereby being obstructed intheir movements from their original or normal closed or uprightpositions to their fully open reclined positions, by the wall.

Zerowall chairs may be manually operating or motorized. Nevertheless,adjusting the seating unit can create substantially large forces,stresses, and torques on the drive components. In addition, the chaircomponents sometimes move (relative to the base rails) as the seatingcomponents, which can shift the balance of the chair and create someinstability. Still further, the drive systems, defined between the drivemotor and the components of the chair, often include relatively complexlinkage arrangements.

SUMMARY

An aspect of the present disclosure includes a motorized positioningapparatus for a seating unit that adjusts relative to a base rail to alesser extent than some previous mechanisms. In addition, the motorizedpositioning apparatus may produce smaller forces, torque, and stressthan some previous devices and may include a simpler linkage mechanism.

In a further aspect, this disclosure describes a motorized positioningapparatus including a set of base rails and a pair of seat plates thatare coupled to one another by a pair of substantially mirror-imagelinkage assemblies. Each linkage assembly includes a footrest-linkageassembly including a plurality of footrest linkages that extend andretract a footrest mounting bracket and that include a footrestactuating link coupled to a respective seat plate. The motorizedpositioning apparatus also includes footrest drive links pivotablycoupled to the footrest actuating link of each linkage assembly. A frontmounting tube is attached to both footrest drive links, and the frontmotor mounting tube may be driven using various motor assemblies, whichmay attach to a rear pivot link of the linkage assembly or may attach toa rear base rail.

Embodiments of the disclosure are defined by the claims below, not thissummary. A high-level overview of various aspects of the disclosure isprovided here for that reason, to provide an overview of the disclosure,and to introduce a selection of concepts that are further describedbelow in the detailed-description section below. This summary is notintended to identify key features or essential features of the claimedsubject matter, nor is it intended to be used as an aid in isolation todetermine the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

This disclosure includes various details that may reference the attacheddrawing figures, which are incorporated herein by reference, wherein:

FIG. 1 is a schematic side elevational view of the right side half of afirst embodiment of a motorized multi-position recliner chair mechanismin accordance with the first embodiment, wherein the chair is disposedat its normally closed, original, upright position;

FIG. 2 is a schematic side elevational view, similar to that of FIG. 1,showing a partially open position at which the footrest has been movedto an extended position and the backrest is disposed in an uprightposition;

FIG. 3 is a schematic side elevational view, similar to that of FIGS. 1and 2, showing a completely open position at which the footrest has beenmoved to an extended position and the backrest has been disposed at areclined position;

FIG. 4 is a perspective elevational view similar to that of FIG. 3;

FIG. 5 is a perspective elevational view similar to that of FIG. 4showing a second embodiment of the motorized multi-position reclinerchair in accordance with the second embodiment;

FIG. 6 illustrates a side top perspective of another linkage mechanismthat is different from the mechanism in FIGS. 1-5, in accordance with anaspect of the present invention;

FIG. 7 illustrates a side top perspective of the linkage mechanism ofFIG. 6 in a partially open configuration, in accordance with an aspectof the present invention;

FIG. 8 illustrates a side top perspective of the linkage mechanism ofFIGS. 6 and 7 in an open and reclined configuration, in accordance withan aspect of the present invention;

FIGS. 9A through 9C depict various views of a drive block that isincluded in the mechanism depicted in FIGS. 6, 7, and 8, in accordancewith an aspect of the present invention;

FIGS. 10, 11, and 12 depict a side view of another linkage mechanismthat is different from the mechanism in FIGS. 1-5 and 6-8, such thatFIGS. 10, 11, and 12 depict a closed configuration, a partially openconfiguration, and an reclined configuration; and

FIG. 13 depicts at least part of a motor assembly that is included inthe mechanism depicted in FIGS. 10, 11, and 12, in accordance with anaspect of the present invention.

DETAILED DESCRIPTION

Subject matter is described throughout this disclosure in detail andwith specificity in order to meet statutory requirements. But theaspects described throughout this disclosure are intended to beillustrative rather than restrictive, and the description itself is notintended necessarily to limit the scope of the claims. Rather, theclaimed subject matter might be practiced in other ways to includedifferent elements or combinations of elements that are similar to theones described in this disclosure and that are in conjunction with otherpresent, or future, technologies. Upon reading the present disclosure,alternative aspects may become apparent to ordinary skilled artisansthat practice in areas relevant to the described aspects, withoutdeparting from the scope of this disclosure. It will be understood thatcertain features and subcombinations are of utility and may be employedwithout reference to other features and subcombinations. This principleis contemplated by and is within the scope of the claims.

Overview of the Motorized Positioning Apparatus for a Seating Unit

This disclosure is generally directed to a motorized mechanism thatoperates to affect a position or arrangement of a seating unit. Forexample, the motorized mechanism may retain a seating unit in, or movethe seating unit into, a closed position, an open position (alsoreferred to as a TV position), and a reclined or extended position. Inaddition this disclosure describes various configurations in which themotor assembly (e.g., motor housing and linear actuator) may be attachedto various portions of the seating unit. More specifically, thisdisclosure describes a motorized mechanism in which a drive block ofmotor assembly attaches to a front drive tube, which attaches to afootrest drive link. In addition, this disclosure describes alternativeconfigurations in which a motor housing may attach to a rear base railor to a rear drive tube attached to a rear pivot link. These variousaspects, as well as the respective features thereof, will be describedin more detail in the various portions of this disclosure.

Exemplary Aspect with Motor Assembly Mounted to Rear Mounting Tube

Referring now to the drawings, and more particularly to FIGS. 1-4thereof, a motorized multi-position recliner chair mechanism isillustrated and is generally indicated by the reference character 100.FIG. 4 is a perspective view of, for example, the right half side of thechair mechanism 100, it therefore being understood and noted furtherthat an opposite mirror image of the chair mechanism componentsillustrated within FIG. 4 would comprise the left half side of the chairmechanism 100 so as to in fact comprise the entire operative chairmechanism 100.

As can be best seen from FIG. 4, the motorized multi-position reclinerchair mechanism 100 is seen to comprise four base rails, only three ofwhich are illustrated at 102, 104, 106, wherein the four base rails 102are disposed within a substantially rectangular array and are supportedupon a ground or floor surface, not shown, by means of downwardlyprojecting feet or leg members 108. For convenience, the three visiblebase rails 102, 104, 106 will be referred to hereinafter as the forwardbase rail member 102, the rearward base rail member 104, and the rightside base rail member 106.

In addition, it is further seen that the chair mechanism 100 comprises adrive motor 110 which has a drive or linear motor actuator 112operatively associated therewith. The drive or linear motor actuator 112can comprise a cylindrical screw having rotary threads formed thereon soas to operatively cooperate and drive an actuator drive block 114forwardly and rearwardly along the actuator 112 as the drive motor 110rotates the drive motor actuator 112, the actuator drive block 114having cooperating threads disposed internally thereof. Other linearactuators, such as, for example, the linear actuator disclosed withinU.S. Pat. No. 8,398,165 which issued to Lawson on Mar. 19, 2013, as wellas the linear actuator disclosed within U.S. Pat. No. 8,573,687 whichissued to Lawson et al. on Nov. 5, 2013, can likewise be utilized. It isfurther seen that the drive motor 110 is pivotally mounted upon, andconnected to, a transversely oriented rear motor mounting tube 116 bymeans of a clevis-type rear motor mounting bracket 118, wherein a lug120 projects outwardly from the drive motor 110 and is pivotallyconnected to the mounting bracket 118 by means of a pivot pin connection122. In a similar manner, it is likewise seen that the actuator driveblock 114 is pivotally mounted upon, and connected to, a transverselyoriented front actuator drive block mounting tube 124 by means of aclevis-type front actuator drive block mounting bracket 126, wherein alug 128 projects outwardly from an upper surface portion of the actuatordrive block 114 and is pivotally connected to the mounting bracket 126by means of a pivot pin connection 130.

With reference continuing to be made to FIG. 4, it is further seen thatthe right end portion of the transversely oriented rear motor mountingtube 116 is fixedly connected to a right rear pivot link 132 by means ofa corner mounting bracket 134. The left end, not illustrated, of therear mount tube 116 is likewise fixedly connected to a corresponding,oppositely disposed rear pivot link, also not illustrated. In thismanner, a first integrally fixed unit is effectively formed by means ofthe rear motor mounting bracket 118, the rear motor mount tube 116, andthe right rear pivot link 132.

The right rear pivot link 132 is, in turn, pivotally connected at thelower end portion thereof to the right side base rail member 106 bymeans of a pivot pin 136, which can best be seen in FIGS. 1-3, and it isto be understood and appreciated further that the pivot pins 122 and 136are coaxially disposed with respect to each other. In this manner, or asa result of this construction of this portion of the chair mechanism100, it can be appreciated that the drive motor 110 is effectivelypositionally fixed, or at least positionally constrained, with respectto the base rail assembly comprising the base rail members 102, 104,106, such that the drive motor 110 does not undergo any significantpositional movement relative to the base rail assembly, other than somepivotal movement as permitted by means of the pivot pin assembly 118,120, 122 as will be necessary when the various components of the chairmechanism linkage system are actuated, as will be more fully explainedhereinafter. Furthermore, this structural relationship impedesasymmetrical moments from being developed when the drive motor 110undergoes pivotal movements whereby, otherwise, such asymmetricalmoments may act upon or be transferred to the various linkage componentsand the base rails 102, 104, 106, possibly rendering the chair mechanism100 unstable. Accordingly, this positional constraint and limitedmovement of the drive motor 110 with respect to the base assemblyprovides enhanced stability for the recliner chair.

In a similar manner, and as will also be more fully discussedhereinafter, chair mechanism 100 likewise comprises a right front pivotlink 138, wherein the lower end portion of the right front pivot link138 is pivotally connected to the right side base rail member 106 bymeans of a pivot pin 140 which can best be seen in FIGS. 1-3. Still yetfurther, and in a manner similar to the fixed connection that wasdefined between the rear pivot link 132 and the rear motor mounting tube116 by means of the corner bracket 134, it is likewise seen that thelower end portion of a footrest drive link 142 is fixedly connected tothe right end portion of the front actuator drive block mounting tube124 by means of a corner mounting bracket 144. In this manner, a secondintegrally fixed unit is effectively formed by means of the frontactuator drive block mounting bracket 126, the front actuator driveblock mounting tube 116, and the footrest drive link 142. In addition,it is also seen that the lower end portion of a pivot link 146 ispivotally connected to the lower end portion of the footrest drive link142 by means of a pivot pin 148 which can best be seen in FIGS. 1-3. Inturn, the upper end portion of the pivot link 146 is pivotally connectedto a first end portion of a drive control link 150 by means of a pivotpin 152, while a second opposite end portion of the drive control link150 is pivotally connected to an intermediate section of the right sidefront pivot link 138 by means of a pivot pin 154.

It will also be seen that the upper end portion of the footrest drivelink 142 is pivotally connected to an intermediate portion of a firstfootrest actuating link 156 by means of a pivot pin 158, while a firstend portion of the first footrest actuating link 156 is pivotallyconnected to a first end portion of a second footrest actuating link 160by means of a pivot pin 162. The second opposite end portion of thesecond footrest actuating link 160 is pivotally connected to a rearportion of a footrest mounting bracket 164 by means of a pivot pin 166,while it is additionally seen that a first end portion of a thirdfootrest actuating link 168 is pivotally attached to an intermediateportion of the footrest mounting bracket 164 by means of a pivot pin170. The second opposite end portion of the third footrest actuatinglink 168 is seen to be pivotally connected to a first end portion of afourth footrest actuating link 172 by means of a pivot pin 174, and thesecond opposite end portion of the fourth footrest actuating link 172 ispivotally connected to a right side seat rail 176 by means of a pivotpin 178. It is also noted that an intermediate portion of the fourthfootrest actuating link 172 is pivotally connected to an intermediateportion of the second footrest actuating link 160 by means of a pivotpin 180, for a purpose that will be discussed more fully hereinafter,and it is also seen that the fourth footrest actuating link 172 is alsoprovided with a contact stop 182 for a purpose which will likewise bediscussed more fully hereinafter. Lastly, with respect to the footrestactuating links 156, 160,168, and 172, it is seen that a second oppositeend portion of the first footrest actuating link 156 is pivotallyconnected to the right side seat rail 176 by means of a pivot pin 184.

Continuing further, it is seen that the upper end portion of the rightside front pivot link 138 is pivotally connected to a first cornerregion of a substantially triangular-shaped recline control link 186 bymeans of a first pivot pin 188, while a second corner region of therecline control link 186 is pivotally connected to the seat rail 176 bymeans of a second pivot pin 190. Still yet further, a third cornerregion of the recline control link 186 is pivotally connected to a firstend portion of a recline connector link 192 by means of a third pivotpin 194, while a second opposite end portion of the recline connectorlink 192 is pivotally connected to a first region of a recline pivotlink 196, which has a substantially inverted L-shaped configuration, bymeans of a first pivot pin 198. Within this region of the mechanismlinkage system, it can also be seen that an intermediate portion of thepivot link 146 is pivotally connected to a substantially central portionof the seat rail 176 by means of a pivot pin 200 which can best be seenin FIG. 3. Reverting back to the substantially inverted L-shaped reclinepivot link 196, it is further seen that a first lower portion of therecline pivot link 196 is pivotally connected to a lower portion of theseat rail 176 by means of a second pivot pin 202, while an upper rearportion of the seat rail 176 has a first corner portion of a seatbacksupport or mounting bracket 204 pivotally mounted thereon by means of apivot pin 206. A second lower portion of the recline pivot link 196 hasa first lower end portion of a backrest recline link 208 pivotallyconnected thereto by means of a third pivot pin 210, while the secondopposite upper end portion of the seatback recline link 208 is pivotallyconnected to the seatback support or mounting bracket 204 by means of apivot pin 212. It is lastly seen that an upper end portion of the rightrear support link 132 is pivotally connected to the outwardly projectingportion of the substantially inverted L-shaped recline pivot link 196 bymeans of a fourth pivot pin 214.

Having now described substantially all of the operating componentsdefining the recliner chair mechanism 100, a brief operation of thesame, for quickly and smoothly moving the various components comprisingthe recliner chair, such as, for example, the footrest mounting bracket164, upon which a chair footrest, not shown, will be mounted, as well asthe backrest support or mounting bracket 204, upon which a chairbackrest, also not shown, will likewise be mounted, between their closed(or retracted) positions to their fully open (or extended) positions,will now be described. It will be seen that the linkage system of thepresent invention mechanism will, in effect, comprise a first linkagesystem which moves the footrest from a closed position to an openposition as a result of the linear movement of the actuator drive blockfrom its original (or start) position to a first predetermined positionalong the drive motor actuator, and a second linkage system which movesthe seatback from an upright position to an inclined position as aresult of the linear movement of the actuator drive block still furtheralong the drive motor actuator from the first predetermined position tothe second predetermined position.

More particularly, with reference being made to FIG. 1, the motorizedmulti-position recliner chair mechanism 100 is disclosed at itsretracted or closed position at which it can be seen that the drivemotor 110 has been actuated such that the actuator drive block 114 isdisposed at its rearward-most position. Accordingly, the footrestmounting bracket 164 is disposed at its closed position at which afootrest, not shown, mounted upon the footrest mounting bracket 164,will be disposed at its closed position at which the footrest will bedisposed in a vertically downward orientation, while the backrestsupport or mounting bracket 204 will be disposed at its uprightposition. When it is desired to initially move the chair from itsoriginal, normally closed position to, for example, a TV position atwhich the footrest is moved from its vertically downward position to anelevated position as disclosed within FIG. 2, the motor drive 106 isactuated so as to move the actuator drive block 114 forwardly withrespect to the drive motor actuator 112 to, for example, the dispositionof the actuator drive block 114 as illustrated within FIG. 2.Accordingly, it can be seen that as the actuator drive block 114 movesforwardly along the drive motor actuator 112, the footrest drive link142 is correspondingly moved forwardly as a result of the first fixedintegral unit defined by or between the actuator drive block 114, theactuator drive block lug 128, the front motor mounting bracket 126, thefront actuator drive block mounting tube 124, and the footrest drivelink 142 fixedly secured to the front actuator drive block mounting tube124 by means of the corner bracket 144. Still further, appreciating thefact that the forward end portion of the footrest drive link 142 ispivotally connected to the first footrest actuating link 156, the firstfootrest actuating link 156 will move in a clockwise direction from itsposition illustrated within FIG. 1 to its position illustrated withinFIG. 2 as a result of pivotal movement around pivot pin 184 whichpivotally secures the first drive control link 142 to the seat rail 176.In turn, the second footrest actuating link 160 is moved forwardly orextended from its position illustrated within FIG. 1 to its positionillustrated within FIG. 2 as a result of its pivotal connection, at itsfirst end portion, to the first footrest actuating link 156 by means ofpivot pin 162.

Recalling that the second opposite end portion of the second footrestactuating link 160 is pivotally connected to the footrest mountingbracket 164 by means of pivot pin 166, the footrest mounting bracket 164is moved toward its forwardmost elevated and horizontally orienteddisposition as a result of the pivotal connection defined between thefootrest mounting bracket 164 and the third footrest actuating link 168.It will also be recalled that an intermediate portion of the secondfootrest actuating link 160 is pivotally connected to the fourthfootrest actuating link 172, which is not only pivotally connected atone end portion thereof to the seat rail 176 by means of pivot pin 178,but the fourth footrest actuating link 172 is also pivotally attached atits opposite end portion to the third footrest actuating link 168 bymeans of pivot pin 174. Accordingly, as the fourth footrest actuatinglink 172 is moved forwardly as a result of the forward movement of thesecond footrest actuating link 160, the fourth footrest actuating link172 will effectively cause the third footrest actuating link 168 to moveupwardly, thereby moving the footrest support bracket 164 to ahorizontal orientation and to a predetermined elevational positionrelative to the base rails 102, 104, 106. This orientation is alsoeffectively predetermined as a result of the predetermined spacingdefined between the pivot pins 166 and 170. Still yet further, thisactuating movement of the various linkage components continues until thestop member 182, disposed upon the fourth footrest actuating link 174,encounters the second footrest actuating link 160. As the footrestsupport bracket 164 is moving forwardly relative to the base rails 102,104, 106 by means of the aforenoted linkage connections, the seat rail176 is also being moved forwardly so as to achieve the desired zerowallfunctional operation of the recliner chair.

More particularly, it will be recalled that the pivot link 146 ispivotally connected to the footrest drive link 142 by means of the pivotpin 148 which can best be seen in FIG. 1. In addition, it will also berecalled that the pivot link 146 is pivotally connected to the seat rail176 by means of the pivot pin 200. Accordingly, as the footrest drivelink 142 is moved forwardly, the seat rail 176 will be moved forwardlyas a result of its pivotal connection to the pivot link 146 which, inturn, is pivotally connected at its lower end portion to the footrestdrive link 142 as at 148, however, the pivot link 146 will also pivot orrotate in the clockwise direction around pivot pin 200, pivotallyconnecting the pivot link 146 to the seat rail 176, causing the secondcontrol drive link 150 to rotate in a clockwise direction. Since theupper end portion of the pivot link 146 is also pivotally connected toone end portion of the second drive control link 150 by means of pivotpin 152, while the second opposite end portion of the second drivecontrol link 150 is pivotally connected to an intermediate portion ofthe right side front pivot link 138 by means of pivot pin 154, it cantherefore be appreciated that the right side front support link 150effectively moves in a counterclockwise direction with respect to thebase rails 102, 104, 106. It is to be noted that the chair mechanism 100is supported by means of the front pivot links 138, only the right sidefront pivot link 138 being illustrated, as well as by means of the rearpivot links 132, only the right side rear support link 132 beingillustrated.

When the recliner chair is moved from the TV position illustrated inFIG. 2, to the fully reclined position illustrated in FIG. 3, andtherefore with reference now being made to FIG. 3, it is noted that theactuator drive block 114 has now been moved to its forwardmost position.Accordingly, the right side pivot link 138 has been rotated stillfurther in the counterclockwise direction, and therefore it is seen thatsuch rotation of the right side pivot link 138 causes thecounterclockwise rotation of the recline control link 186 relative tothe seat rail 176 as a result of the pivotal connection of the reclinecontrol link 186 to the seat rail 176 by means of the pivot pin 190. Itwill be recalled that one end portion, that is, the left end portion, ofthe recline connector link 192 is pivotally connected to the reclinecontrol link 186, while the opposite or right end portion of the reclineconnector link 192 is pivotally connected to the recline pivot link 196.Therefore, as the recline control link 186 rotates or pivots in acounterclockwise direction, the recline connector link 192 willeffectively be moved toward the right or rearwardly. Such rightward orrearward movement of the recline connector link 192 will, in turn, causeclockwise rotation of the recline pivot link 196 around pivot pin 202that pivotally connects the recline pivot link 196 to the seat rail 176.Rotational movement of the recline pivot link 196, in turn, results inthe downward movement of the backrest recline link 208 as a result ofthe pivotal connection of the lower end portion of the backrest reclinelink 208 to the recline pivot link 196 by means of pivot pin 210. Thedownward movement of the backrest recline link 208 therefore causes theseatback support or mounting bracket 204 to be rotated in a clockwisedirection relative to the seat rail 176, around pivot pin 206, as aresult of the pivotal connection defined between the seatback reclinelink 208 and the seatback support or mounting bracket 204 by means ofpivot pin 212. It is to be lastly understood that the driving of drivemotor 110 in a reverse mode will effectively reverse all of theaforenoted movements of the various mechanism linkages such that thechair mechanism 100 can be moved and returned from its fully reclineposition, illustrated within FIGS. 3 and 4, to the intermediate andoriginal positions respectively illustrated within FIGS. 2 and 1.

Exemplary Aspect with Motor Assembly Mounted to Rear Base Rail

With reference now being made to FIG. 5, another embodiment of amotorized multi-position recliner chair mechanism is disclosed and isgenerally indicated by the reference character 300. It is to be notedthat component parts of the second embodiment chair mechanismillustrated within FIG. 5, that correspond to component parts of thefirst embodiment chair mechanism illustrated within FIG. 1, will bedenoted by similar reference characters except that such referencecharacters will be in the 300 and 400 series. In addition, for brevitypurposes, a description of those structural components which are commonto both embodiments, and which are operationally similar, will not bediscussed in detail, the description of the second embodimentillustrated within FIG. 5 being limited to the structural differencesbetween the first and second embodiments.

More particularly, it can readily be seen that a difference of the chairmechanism 300 as illustrated within FIG. 5, when compared to the chairmechanism 100 disclosed within FIGS. 1-4, resides in the fact that therear motor mounting tube has effectively been eliminated. As a result ofthis structural change, it is seen that in lieu of the drive motor 310of the chair mechanism 300 being mounted upon the rear motor mountingtube, the drive motor 310 is pivotally attached directly to the rearbase or floor rail 304. In addition, it is likewise seen that the rightrear pivot link 332 is likewise connected directly to the right baserail 306.

Alternative Exemplary Aspect with Motor Assembly Mounted to Rear BaseRail

Referring now to FIGS. 6-8 and 9A-9C, another embodiment of the presentinvention is illustrated. FIGS. 6, 7, and 8 depict the mechanism in aclosed position, TV position, and reclined position (respectively). Inaddition, FIGS. 9A-9C provide a more detailed illustrative view of thedrive block 514 that is included in the mechanism of FIGS. 6, 7, and 8.

It is to be noted that many of the component parts of the thirdexemplary aspect of the mechanisms illustrated within FIGS. 6-8 aresimilar to the components illustrated in FIGS. 1-5. These componentparts that are similar or that function in a similar manner, for brevitypurposes, are not described in detail. Rather, the description of FIGS.6-8 and 9A-9C will be directed to some of the differences included inthe third exemplary aspect.

In FIGS. 6-8, similar to FIG. 5, the motor assembly attaches to a rearbase rail 504 and to a front mounting tube 524. For example, aclevis-style bracket (e.g., lug) 520 extends from the motor housing. Theclevis-style bracket 520 might be a separate bracket that is attached tothe housing, or the clevis-style bracket 520 might be integrally formed(e.g., co-molded with) the rest of the motor housing. In addition, oneor more rear motor-mounting brackets 518 are attached directly to therear base rail 504.

The clevis-style bracket 520 and the rear motor-mounting bracket 518 arepivotably coupled to one another, such as by a clevis pin. To achievedesired positioning of the motor mechanism (e.g., motor drive 510, motorlinear actuator 512, and drive block 514) the rear motor-mountingbracket 518 includes a leg extension that extends forward from the rearbase rail 504 (i.e., forward towards a front base rail), such that thepivotable connection with the clevis-style bracket 520 is forward of therear base rail 504.

In the aspect depicted in FIGS. 6-8, the front mounting tube 524 isattached to the footrest drive link 542 by way of a mounting bracket544. The mounting bracket 544 and the footrest drive link are coupled bytwo mechanical fasteners (e.g., pins, screws, bolts, and the like) atfastener apertures 588 and 590, the two fasteners providing anon-rotating connection between the mounting bracket 544, the footrestdrive link 542, and the front mounting tube 524.

The motor mechanism of FIGS. 6-8 includes an actuator drive block 514that slidably traverses the linear actuator 512. A clevis-styleattachment arrangement attaches the actuator drive block 514 to amounting bracket 526, which is coupled to the front mounting tube 524.As compared with the actuator drive block 114 of FIGS. 1-5, the pivotingconnection that attaches the drive block 514 to the mounting bracket 526is located forward of the block 514, as will be described in more detailbelow.

Referring now to FIGS. 9A-9C, additional illustrative aspects of thedrive block 514 are depicted. The drive block 514 includes a block body550 that is configured to slidably traverse the linear actuator 512. Forexample, the block body 550 includes a top wall 552 and side walls 554Aand 554B that at least partially enclose an actuator receiving space556. Among other features, the actuator receiving space 556 may includea through hole 558 through which a cylindrical screw (or other actuatormechanism) may be threaded or otherwise inserted. In addition, the blockbody 550 includes a front end 560 that is oriented towards the front ofthe seating unit when the block 514 is affixed to the a motor assemblythat is mounted to a front mounting tube, such as depicted in FIGS. 6-8.

The block body also includes a left mounting tab 562A and a rightmounting tab 562B that extend from the front end 560 of the block body550 and above the top wall 552. Each of the mounting tabs 562A and 562Bincludes a respective pin-receiving aperture 564A and 564B for receivinga pin that attaches the block 514 to the mounting bracket 526, which isaffixed to the front mounting tube 524. The pin-receiving apertures 564Aand 564B are positioned such that the pivoting connection between themotor block 514 and the mounting bracket 526 is both in front of thefront end 560 and is above the top wall 560 (as well as above the linearactuator). Although the illustrative figures depict two mounting tabs,the mounting block might have a single mounting tab or more than twomounting tabs.

Referring to FIG. 9B, the pin-receiving apertures (e.g., 564A) arespaced a distance 566 from the front end 560 of the motor block 514. Inone aspect of the disclosure, the distance 566 is in a range of about 30mm to about 35 mm from the center axis of the aperture to the front edgeof the block body. In a further aspect, the distance 566 is about 32 mmfrom the aperture center axis to the front edge.

The drive block 514 includes other features as well. For example, thepin-receiving apertures 564A and 564B are spaced a distance 568 abovethe center line of the through hole 558, in which a motor screw may bepositioned. In one aspect of the disclosure, the distance 568 is in arange of about 33 mm to about 37 mm from the center line of the throughhole 558 to the axis of the apertures 564A and 564B, and in a furtheraspect, the distance 568 is about 35 mm. When the block 514 is affixedto the mounting bracket 526, this forward position of the clevis pin,which results from distance 566, distance 568, or a combination ofdistances 566 and 568, helps to minimize the up and down rotation of themotor during movement of the mechanism through its positions depicted inFIGS. 6-8. Minimizing up and down movement of the mechanism can behelpful to avoid, or at least reduce, interference with other componentsof the seating unit (i.e., clearance issues). In addition, the forwardposition helps to reduce the overall length of the motor mechanism,since if the pivot attachment were positioned further rearward, ordirectly over the block, then the actuator 512 would need to be longerin order for the block 514, mounting bracket 526, and front mountingtube 524 to achieve the same forward position depicted in FIG. 8. Thismight result in a motor mechanism that is too long to fit within somechair mechanisms. As can be seen in FIG. 8, the overall length of theactuator 512 can be reduced or shortened because the forward position ofthe pin-receiving apertures (e.g., 564B in FIG. 8) allows the pivotconnection to travel past the end of the actuator 512 at the end of thelinear stroke.

As depicted, the drive block 514 includes a block width 570, including adistance between the outward-facing surfaces (e.g., 572A) of the leftwall 554A and the right wall 554B. In one aspect of the disclosure, thedistance 568 is in a range of about 50 mm to about 65 mm from theoutward-facing surface 572A of the left wall 554A to the outward-facingsurface (not viewable in FIGS. 9A-9C) of the right wall 554B, and in afurther aspect, the width 570 is about 62 mm. As indicated above, thedrive block 514 might include a single mounting tab, which would alsoinclude the width 570.

In some instances, the width 570 may directly affect the synchronizationof the left linkage mechanism (not depicted) and the right linkagemechanism (e.g., 300), since a width that is too narrow may allow forthe mounting tube 524 to skew as the motor block 514 traverses theactuator 512. That is, the sides of the mounting tube (e.g., right sideor left side) may travel at different rates if the width 570 of theblock 514 is too narrow and does not provide a sufficiently stable drivepoint. In this manner the width 570 that is in a range of about 50 mm toabout 65 mm, and possibly about 62 mm, helps to maintain synchronizationof the linkage mechanism.

Alternative Exemplary Aspect with Motor Assembly Mounted to RearMounting Tube

Referring now to FIGS. 10-13, another embodiment of the presentinvention is illustrated. FIGS. 10, 11, and 12 depict the mechanism in aclosed position, TV position, and reclined position (respectively). Inaddition, FIG. 13 provides a more detailed illustrative view of themotor mechanism 600 that is included in the mechanism of FIGS. 10, 11,and 12.

It is to be noted that many of the component parts of the fourthexemplary aspect of the mechanisms illustrated within FIGS. 10-12 aresimilar to the components illustrated in FIGS. 1-8. These componentparts that are similar or that function in a similar manner, for brevitypurposes, are not described in detail. Rather, the description of FIGS.10-13 will be directed to some of the differences included in the fourthexemplary aspect.

Similar to FIGS. 1-4, the motor mechanism 600 attaches to a rearmounting tube 616 and to a front mounting tube 624. For example, aclevis-style bracket (e.g., lug) 620 extends from the motor housing 630.As previously indicated, the clevis-style bracket 620 might be aseparate bracket that is attached to the housing 630, or theclevis-style bracket 620 might be integrally formed (e.g., co-moldedwith) the rest of the motor housing 630. In addition, a rearmotor-mounting bracket 618 is attached directly to the rear mountingtube 616. The clevis-style bracket 620 and the rear motor-mountingbracket 618 are pivotably coupled to one another, such as by a clevispin passing through the pin-receiving aperture 622. In addition, therear mounting tube 616 attaches to the rear pivot link 632 by way of amounting bracket 634 in a non-rotating manner, such that the rearmounting tube 616 does not rotate relative to the rear pivot link 632.In addition, the motor 610 is effectively mounted above the lower pivot636 of the rear pivot link based on the relative location of thepin-receiving aperture 622 connecting the clevis-style bracket 620 tothe mounting bracket 618. That is, in FIG. 10 the pin-receiving aperture622 is above the lower pivot 636 that attaches the rear pivot link tothe base rail. The configuration of the various components, such as theclevis-style bracket 620, the rear motor-mounting bracket 618, and themounting bracket 634 positions the pin-receiving aperture 622 a distanceabove the pivot connection 636. In aspect of the disclosure, thepin-receiving aperture 622 is located about 30 mm to about 40 mm higherthan the pivot connection 636, and may be about 35 mm higher.

The motor mechanism of FIGS. 10-13 includes an actuator drive block 614that slidably traverses the slide actuator 612. A clevis-styleattachment arrangement is utilized to attach the actuator drive block614 to a mounting bracket 626, which is coupled to the front mountingtube 624. As compared with the actuator drive block 514 of FIGS. 6-9,the clevis pin-receiving aperture 664 that attaches the actuator driveblock 614 to the mounting bracket 626 is located directly above theblock 614, as opposed to a forward orientation in front of the frontedge of the drive block. In addition, the front mounting tube 624non-rotatably attaches to a footrest drive link 642 by way of a mountingbracket 644, in the same manner as describe with respect to themechanism of FIGS. 6-8.

As depicted in FIGS. 10-12, the motor 610 is attached in an upside-downorientation, relative to FIGS. 1-8, and this aspect is furtherillustrated in FIG. 13. That is, in FIGS. 10-12, the portion of themotor housing that is oriented downwards and facing towards the groundsurface (not actually depicted) is oriented upward and toward the seatplates in FIGS. 1-8. In FIG. 13, the motor assembly includes a top side602, which is generally oriented towards the direction of the seat plateof the seating mechanism when installed in a seating unit, and a bottomside 604, which is generally oriented towards and facing the directionof the ground surface or base rails. In addition, the drive block 614includes one or more mounting tabs 662 that extend from the drive block614 and in the direction towards the seat plates, the one or moremounting tabs 662 including the pin-receiving aperture 664 for attachingthe drive block 614 to the mounting bracket 626. As depicted in FIG. 13,the motor mechanism 600 includes a distance 680 between a center line ofthe pin-receiving aperture 622 (of the lug 620) and a center line of thepin-receiving aperture 664. (The centerline of the pin-receivingaperture 622 may also be substantially aligned with the centerline of amotor screw threadably extending through the body of the drive blow614.) In an aspect of the disclosure, the distance 680 is in a range ofabout 18 mm to about 22 mm, and may be about 20 mm. Moreover, the motorhousing 630 extends from the bottom side of the motor assembly and in adirection opposite the mounting tabs 662 (i.e., towards the base rails),and the motor mechanism 600 includes a distance 682 between a lowermostsurface of the motor housing 630 and the center line of thepin-receiving aperture 622 (of the lug 620). In an aspect of thedisclosure, the distance 682 is in a range of about 52 mm to about 58mm, and may be about 55 mm.

This orientation and the distances 680 and 682 may be helpful inchair-mechanism configurations in which the chair frame would otherwisehave a difficult time clearing the motor 610, when attached to the rearbase rail (as in FIGS. 6-8). By attaching the motor 610 above the lowerpivot 636 of the rear pivot link 632 on the mechanism, the motor 610moves forward as the mechanism opens from the closed position to the TVposition and/or to the recline position, causing the motor 610 to moveout of the way of the rear of the chair frame as the chair reclines.Further, mounting the motor mechanism 600 upside down locates theclevis-pin connection 622 higher, while positioning the motor housing630 closer to the floor. This combination of orientations allows themotor mechanism 600 to fit between the rear pivot link 632 and afootrest board (not shown but would be attached vertically and slightlyforward of the front base rail 602), and to still provide the necessarystroke to move the linkage mechanism through the desired positions. Thisconfiguration locates the motor in a limited area that provides frameclearance and floor clearance while allowing for a short enough motorlength to fit within the confines of the chair.

Although not specifically illustrated, the drive block 614 may include awidth that is similar to the width 570 and that helps to maintainsubstantial synchronization between the mechanisms. For example, a widthof the drive block 614 may be between 50 mm and 65 mm, and may be 53 mm.

FIGS. 11 and 12 depict the seating mechanism in a TV position andreclined position, respectively, when the drive block 614 has traversedthe actuator 612. Among other things, FIGS. 11 and 12 illustrate thatthe motor housing 630 traverses a relatively small distance as themechanism transitions through its various positions, such as byconsidering the relatively small movement of the pin-receiving aperture622. For example, in one aspect, the forward traversal of the motorhousing from the closed position in FIG. 10 to the reclined position inFIG. 12 is in a range of about 18 mm to about 22 mm, and may be about 20mm, which results in part from the rear pivot link rotating forward.

Other Aspects

This disclosure includes additional aspects, and when describing theseadditional aspects, reference may be made to one or more of the figuresdescribed in other portions of this disclosure. For example, a furtheraspect of the disclosure includes a motorized positioning apparatus fora seating unit, the apparatus including a set of base rails and a pairof seat plates that are coupled to one another by a pair ofsubstantially mirror-image linkage assemblies. Each linkage assemblyincludes a footrest-linkage assembly including a plurality of footrestlinkages that extend and retract a footrest mounting bracket and thatinclude a footrest actuating link coupled to a respective seat plate.The motorized positioning apparatus also includes footrest drive links(e.g., 142, 342, 542, and 642) pivotably coupled to the footrestactuating link of each linkage assembly. In addition, a front mountingtube (e.g., 124, 324, 524, and 624) is attached to both footrest drivelinks. The front motor mounting tube may be driven using various motorassemblies, such as the motor assembly depicted in FIGS. 6-8 includingthe drive block 514 depicted in FIGS. 9A-9C. In addition, the frontmotor mounting tube may be driven by the motor assembly depicted in FIG.13.

From the foregoing, it will be seen that aspects herein are well adaptedto attain all the ends and objects hereinabove set forth together withother advantages which are obvious and which are inherent to thestructure. It will be understood that certain features andsubcombinations are of utility and may be employed without reference toother features and subcombinations. This is contemplated by and iswithin the scope of the claims. Since many possible aspects may be madewithout departing from the scope thereof, it is to be understood thatall matter herein set forth or shown in the accompanying drawings is tobe interpreted as illustrative and not in a limiting sense.

The invention claimed is:
 1. A motorized positioning apparatus for aseating unit, the apparatus comprising: a set of base rails including afirst side base rail, a second side base rail, a front base rail, and arear base rail, the front and rear base rails being coupled between thefirst side base rail and the second side base rail, the set of baserails forming at least part of a support base for the seating unit; apair of seat plates including a first seat plate positioned above thefirst side base rail and a second seat plate positioned above the secondside base rail; a pair of substantially mirror-image linkage assembliesincluding a first linkage assembly coupling the first seat plate to thefirst side base rail and a second linkage assembly coupling the secondseat plate to the second side base rail, the first and second linkagemechanisms each including: a footrest-linkage assembly including aplurality of footrest linkages that pivotably adjust to extend andretract a footrest mounting bracket and that include a footrestactuating link coupled to a respective seat plate; and a footrest drivelink pivotably coupled to the footrest actuating link; a front motormounting tube including a first end mounting bracket and a second endmounting bracket, the first end mounting bracket being coupled to afirst footrest drive link of the first linkage assembly and the secondend mounting bracket being coupled to a second footrest drive link ofthe second linkage assembly; a motor assembly coupled to the front motormounting tube and to the rear base rail, the motor assembly including adrive block that slidably traverses a linear actuator, the drive blockbeing coupled to the front motor mounting tube by a tube mountingbracket, the motor assembly including a motor housing pivotably attachedto the rear base rail, wherein the drive block includes a block bodyhaving a front terminal end facing away from the motor housing andtowards a front end of the linear actuator; wherein the drive blockincludes an actuator receiving space having a through-hole centerline;and wherein the drive block includes one or more mounting tabs thatinclude a pin-receiving aperture for receiving a fastener attaching thedrive block to the tube mounting bracket, the pin-receiving aperturebeing positioned a distance above the through-hole centerline and infront of the front terminal end, toward the front end of the linearactuator.
 2. The apparatus of claim 1, wherein a centerline of thepin-receiving aperture is spaced a distance from the front terminal end,and wherein the distance is in a range of about 30 mm to about 35 mm. 3.The apparatus of claim 1, wherein a distance from the centerline of thepin-receiving aperture, and wherein the distance is in a range of about33 mm to about 37 mm.
 4. The apparatus of claim 1, wherein the one ormore mounting tabs includes a width in a range of about 50 mm to about65 mm.
 5. The apparatus of claim 4, wherein the width is about 62 mm. 6.A motorized positioning apparatus for a seating unit, the apparatuscomprising: a set of base rails forming at least part of a support basefor the seating unit; a pair of seat plates positioned above, and spacedapart from, the set of base rails; a pair of substantially mirror-imagelinkage assemblies including a first linkage assembly coupling a firstseat plate of the pair of seat plates to a first side base rail of theset of base rails, the pair of substantially mirror-image linkageassemblies including a second linkage assembly coupling a second seatplate of the pair of seat plates to a second side base rail of the setof base rails, the first and second linkage mechanisms each including: afootrest-linkage assembly including a plurality of footrest linkagesthat pivotably adjust to extend and retract a footrest mounting bracketand that include a footrest actuating link coupled to a respective seatplate; a footrest drive link pivotably coupled to the footrest actuatinglink; and a rear pivot link that attaches by way of a pivot connectionto a respective side base rail; a front motor mounting tube coupled tothe footrest drive links; a motor assembly coupled to the front motormounting tube and to a rear motor mounting tube, the motor assemblyincluding a drive block that slidably traverses a linear actuator, thedrive block being coupled to the front motor mounting tube by afront-tube mounting bracket, the motor assembly including a motorhousing pivotably attached to the rear motor mounting tube, wherein themotor housing includes a motor mounting bracket having a pin-receivingaperture for receiving a pin and coupling the motor mounting bracket toa rear-tube mounting bracket; wherein the rear motor mounting tubeincludes a first end mounting bracket and a second end mounting bracket,the first end mounting bracket being coupled to a first rear pivot linkof the first linkage assembly and the second end mounting bracket beingcoupled to a second rear pivot link of the second linkage assembly; andwherein pivot connections attaching the rear pivot links to the siderails are spaced a distance below the pin-receiving aperture of themotor mounting bracket, the distance being in a arrange of about 30 mmto about 40 mm.
 7. The apparatus of claim 6, wherein the distance isabout 35 mm.
 8. The apparatus of claim 7, wherein the motor housingincludes a lower surface that generally faces in a direction of the setof base rails and away from a direction of the seat plates, and whereinthe lower surface and a centerline of the pin-receiving aperture of themotor mounting bracket are spaced apart by a distance in a range ofabout 52 mm to about 58 mm.
 9. The apparatus of claim 8, wherein thedrive block includes one or more mounting tabs that include apin-receiving aperture for receiving a fastener attaching the driveblock to the front-tube mounting bracket, the one or more mounting tabsextending in a direction of the seat plates and away from a direction ofthe base rails, and wherein a centerline of the pin-receiving apertureof the one or more mounting tabs is spaced a distance from thecenterline of the pin-receiving aperture of the motor mounting bracket,the distance being in a range of about 18 mm to about 22 mm.
 10. Theapparatus of claim 6, wherein the first and second linkage mechanismsare configured to move from a closed position to a TV position and fromthe TV position to a reclined position, and wherein the motor housingmoves a distance in a direction of the footrest linkage assembly whenthe first and second linkage assemblies move from the closed position tothe reclined position, the distance being less than about 22 mm.